Automotive vehicle seat insert

ABSTRACT

There is disclosed an insert suitable for placement within a seat of an automotive vehicle. The insert preferably includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also preferably includes a blower or air pump for providing ventilation and/or cooling to the seat occupant.

CLAIM OF PRIORITY

[0001] To the extent applicable, the present invention claims thebenefit of the priority of U.S. Provisional Application Serial No.60/393,815, filed Jul. 3, 2002 and U.S. Provisional Application SerialNo. 60/433,270, filed Dec. 13, 2002, both of which are incorporatedherein by reference for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates generally to automotive vehicleseats, and more particularly to an insert for providing heating,cooling, ventilation or a combination thereof to a seat of an automotivevehicle.

BACKGROUND OF THE INVENTION

[0003] For many years the transportation industry has been concernedwith designing seats for automotive vehicles that provide added comfortto occupants in the seats. Various innovations in providing seatingcomfort are discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065;6,048,024 and 6,003,950, all of which are expressly incorporated hereinby reference for all purposes. In addition, other innovations inproviding seating comfort are discussed in U.S. patent application Ser.No. 09/619,171, filed Jul. 19, 2000, titled “Ventilated Seat Having aPad Assembly and a Distribution Device”; U.S. patent application Ser.No. 09/755,505, filed Jan. 5, 2001, titled “Ventilated Seat”; and U.S.patent application Ser. No. 09/755,506, filed Jan. 5, 2001, titled“Portable Ventilated Seat”, each of which are expressly incorporatedherein by reference for all purposes. In the interest of continuing suchinnovation, the present invention provides an improved seating system,insert for a seat or both, which are preferably suitable for employmentwithin or as part of an automotive vehicle seat and which assist inproviding comfort control to an occupant in the seat.

SUMMARY OF THE INVENTION

[0004] According to the present invention, there is disclosed a seatinsert, a method of forming the seat insert and a ventilated seat thatis preferably suitable for an automotive vehicle. The insert preferablyincludes a forward layer, a rearward layer and a middle layer, althoughgreater or fewer layers may be included. When included, the forwardlayer typically includes a first barrier sub-layer, a heater sub-layer,a plurality of openings or a combination thereof. In preferredembodiments, the first barrier sub-layer is formed of a plasticmaterial, the heater sub-layer is formed as a lay-wire heater or both.

[0005] The rearward layer, when included, has a second barriersub-layer, an opening or both. In a preferred embodiment, the secondbarrier sub-layer is formed of a plastic material like the first barriersub-layer. The middle layer typically includes a spacer sub-layerdefining an open space. In a preferred embodiment, the spacer sub-layeris formed of interwoven polymeric strand material. An air mover (e.g., ablower) is attached to the insert and is preferably at least partiallydisposed within the at least one opening of the rearward layer, althoughnot required. The air mover is in fluid communication with the pluralityof openings in the forward layer, the open space of the spacer sub-layeror both.

[0006] During formation of the insert, the first barrier sub-layer ispreferably sealingly attached to the second barrier sub-layer about aperiphery of the insert, although other attachments may be employed. Theblower is preferably configured to pull air through the plurality ofopenings in the forward layer and through the open space of the spacersub-layer, but it may also push air through these areas.

[0007] When assembled to a seat (e.g., a vehicle seat), the seatpreferably includes a seat cushion component and a seat backrestcomponent. At least one of the components is typically ventilated by theinsert and each ventilated component typically includes an air-permeabletrim surface at occupant contact areas of the seat. The insert ispreferably located beneath the trim surface of each ventilatedcomponent.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The features and inventive aspects of the present invention willbecome more apparent upon reading the following detailed description,claims and drawings, of which the following is a brief description:

[0009]FIG. 1 is a blown up perspective view of a seat insert inaccordance with an exemplary aspect of the present invention;

[0010]FIG. 2 is a flow diagram for producing seat inserts in accordancewith an exemplary aspect of the present invention;

[0011]FIG. 3 is a partially cut-away elevational view of the seat insertof FIG. 1 after assembly of the insert;

[0012]FIG. 4 is a sectional view of the insert of FIGS. 1 and 3 takenalong line 4-4 in FIG. 3;

[0013]FIG. 5 is a perspective view of an exemplary blower suitable forapplication in the insert of the present invention; and

[0014]FIG. 6 is a sectional view of the insert attached in an exemplarymanner to a seat of an automotive vehicle according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention is predicated upon providing an insertsuitable for placement within an automotive vehicle seat to provideheating, cooling, ventilation or a combination thereof to an occupant inthe seat. The insert will include at least one layer, but preferablyincludes multiple (e.g., three) layers and each of the layers mayinclude one or more sub-layers. For example, one of the layerspreferably incorporates a heater or heater sub-layer into the insert.One or more of the layers also preferably incorporates a plastic filmsub-layer for assisting in lamination of the layers, for providing a gasbarrier or both. It is also preferable for one or more of the layers toprovide a spacer sub-layer for providing open space within the insert.Additionally, a blower may be incorporated into the insert for providingfluid flow through the insert.

[0016] Referring to FIGS. 1 and 3-5, there is illustrated an exemplaryinsert 10 suitable for placement within a seat of an automotive vehicle.The insert 10 preferably includes a plurality of layers that may beseparate but are preferably attached to each other to form the insert.In the embodiment shown, the insert 10 includes a first or forward layer14 (e.g., the layer of the insert configured to be closest an occupantof the seat), a second or middle layer 16 and a third or rearward layer20 (e.g., the layer of the insert configured to be furthest from theoccupant of the seat).

[0017] It is preferred that one of the layers 14, 16, 20 includes aheater. In the embodiment depicted, the forward layer 14 includes aheater sub-layer 26, which is preferably laminated to a gas barriersub-layer 28 (e.g., a film, a textile or otherwise) although such filmis not necessarily required. Various different types of heaters aresuitable for incorporation into a car seat and it is contemplated thatany of such heaters may be incorporated into the insert 10 of thepresent invention. Such heaters typically incorporate flexibleelectrical heating elements that are preferably thin, flat,non-obtrusive or a combination thereof. As examples, a lay-wire heater,a carbon fiber heater, a positive thermal coefficient (PTC) heater, athermoelectric heater or the like, which are typically supported with abacking (e.g., a cloth or fabric type backing) may be used within theinsert. In a preferred embodiment, the heater sub-layer 26 is a carbonfiber type heater with a backing (e.g., a nonwoven layer). One exemplarypreferred heater is sold under the tradename CARBOTEX® and commerciallyavailable from W.E.T Automotive Systems, Inc. in Germany and/or FTGFraser-Technik GmbH, Schleizer Strasse 56-58, D-95028 Hot/Saale,Germany. An example of such a heater is disclosed in U.S. Pat. No.6,064,037, issued May 16, 2000, herein expressly incorporated byreference for all puposes.

[0018] When included, the barrier sub-layer 28 is typically formed of aplastic or polymeric material that softens or melts upon exposure toheat to assist the sub-layer 28 to adhere to one or more other layers orsub-layers. Alternatively, the barrier sub-layer 28 may be formed offabrics, woven materials (e.g., goretex or microfibers), nylon, closedpore foam or other materials. Preferably, the barrier sub-layer 28 issubstantially impermeable to fluids and particularly air such that thesub-layer 28 can assist in forming an air barrier as will be describedfurther herein. Dimensionally, for a film barrier sub-layer, it ispreferable for the film thickness to be about 0.1 mm to about 2.0 mmthick and more preferably about 0.7 mm to about 1.0 mm thick. Of course,it is contemplated that the film sub-layer 28 may have a variablethickness and may be outside of the aforementioned ranges.

[0019] The first layer 14 may also include one or more buffersub-layers, one or more adhesives or adhesive sub-layers, one or moretape sub-layers, one or more porous foam layers or a combinationthereof. Adhesive may be supplied in layers, drops or in a variety ofother configurations. Preferably, the buffer layer is at least partiallyformed of an insulating material.

[0020] In the preferred embodiment depicted, the first layer 14 includestwo adhesive sub-layers 34, one strip of tape 36 and one buffersub-layer 38. The adhesive sub-layers 34 are preferably formed of a hotmelt adhesive although not necessarily required. The adhesive may beprovided as a web or otherwise and may be continuous or non continuous(e.g., may be applied in drops, dabs or the like). The adhesivesub-layers may include polyamides, polyesters, elastomers, urethanes,olefin polymers or a combination thereof. Moreover, the adhesives may beformulated as desired for particular processing parameters orconditions. Preferably, the adhesive sub-layers are substantially freeof anti-blocking solutions, blowing additives, process contaminants orthe like which might interfere with adhesive performance. As an example,one suitable hot melt adhesive is commercially available as a non-wovenweb under the tradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane,Cuyahoga Falls, Ohio 44223.

[0021] The buffer sub-layer 38 in the embodiment depicted is a layer ofgauze which is capable of protecting the heater layer 20 althoughvarious alternative protective materials may be used such as cloth,fleece or the like. The tape 36 is preferably tacky on two sides.

[0022] According to an alternative embodiment, it is contemplated thatthe first layer 14 may also include an air-permeable layer (not shown)between buffer sub-layer 38 and an occupant of the seat. Theair-permeable layer, which may be any one of a variety of air-permeablematerials (such as reticulated foam, for example) may be able to helpdistribute air under the occupant.

[0023] One of the layers 14, 16, 20, preferably the middle layer 16,includes a spacer sub-layer 48 formed of a spacer material. The spacermaterial may be provided as a variety of synthetic materials such asplastic or polymeric materials, padding and stuffing materials, liningand carrier materials or the like. Preferably, the spacer materialcreates a sub-layer 48 that functionally provides open space within thesub-layer while remaining at least partially pliable or flexible betweenthe first and third layers 14, 20. As one example, the spacer sub-layermay be provided as a plurality of rubber, foam plastic or other membersor fibers. The members or fibers are preferably spaced apart from eachother to provide open space therebetween while still being close enoughtogether to provide cushion and support. As another example the spacersub-layer 48 may be formed of a 3-dimensional spacer fabric structure ormaterial.

[0024] In the preferred embodiment depicted, the middle layer 16includes only the spacer sub-layer 48, however, it is contemplated thatadditional sub-layers (e.g., adhesive sub-layers) or other materials(e.g., adhesives) may be incorporated into the middle layer 16. Theparticular sub-layer 48 shown is formed of polymeric (e.g., polyester)strand material that is interwoven to provide opposing honeycombstructures 56 (e.g., fabric panels), which are interconnected by severaladditional polymeric strand materials to provide open space 58 betweenthe structures 56 while still providing cushion and support. As anexample, one preferred material is sold under the tradename 3MESH® andis commercially available from Müller Textil GmbH, Germany or MüllerTextiles, Inc., Rhode Island, USA.

[0025] In another of the layers 14, 16, 20 of the insert 10, preferablythe rearward layer 20, there is included an outer protective or buffersub-layer and another barrier sub-layer. In the embodiment shown, oneintegrated sub-layer 62 provides the both the barrier sub-layer 66 andthe outer protective sub-layer 68 although they may be providedseparately. The barrier sub-layer 66 for the rearward layer 20 may bethe same or different than the barrier sub-layer 28 of the forward layer14.

[0026] Preferably, the protective sub-layer 68 is formed of a fleecematerial, however, various other materials may be used such as gauze,cloth, fabric or the like. It is also preferable for the rearward layer20 to include an adhesive or adhesive sub-layer 70 similar to or thesame as those discussed in relation to the forward layer 14. Accordingto a preferred embodiment, the adhesive sub-layer 70 is providedintegrally with the integrated sub-layer 62.

[0027] In a highly preferred embodiment, an attachment component 72 isincluded in one of the layers 14, 16, 20. The attachment component 72shown in FIG. 1 is a frame member that preferably defines an opening orthrough-hole 74. It is contemplated that the frame member may be in avariety of configurations (e.g., annular, rectangular, square, geometricor otherwise) and may be formed of a variety of preferably rigid orsemi-rigid materials (metal, plastic or the like).

[0028] Notably, several of the materials of the various layers andsub-layers of the insert 10 may be environmentally friendly. Forexample, and without limitation, the materials of the spacer sub-layer48, the buffer and protective sub-layers 38, 68 and the barriersub-layers 28, 66 may be recyclable.

Assembly

[0029] Generally, for forming a vehicle seat insert according to thepresent invention, it is contemplated that the various layers andsub-layers of the insert as described above may be combined in a varietyof sequences and according to a variety of protocols and technique.Thus, the order in which the various layers and sub-layers are combinedand the techniques of combining should not in any way limit the presentinvention unless such order or techniques is specifically claimed.Moreover, it is also contemplated that there may be greater or fewerlayers and that each layer may include greater or fewer sub-layers.

[0030] According to a preferred method, the sub-layers of the front orfirst layer and the third or rearward layer are each laminatedseparately followed by laminating the front layer to the rearward layerwith the middle layer in between. Referring to FIGS. 1 and 2, the firstlayer 14 is formed according to a preferred method by feeding thevarious sub-layers 38, 26, 28 to a laminator 80 (e.g., a belt and rollerlaminator).

[0031] Although the manner in which the sub-layers 38, 26, 28 are fed tothe laminator 80 may be varied, the preferred embodiment has the buffersub-layer 38 and one of the adhesive sub-layers 34 as the outersub-layers on the outer sides of the first layer 14. The barriersub-layer 28 and the heater sub-layer 26 are directly inside of theouter sub-layers and, as shown, the other adhesive sub-layer 34 isbetween the barrier sub-layer 28 and the heater sub-layer 26.Preferably, the tape 36 is integrated into the first layer 14 betweenthe buffer sub-layer 38 and the heater sub-layer 26 such that the tape36 may be used to form a pocket for securing a wire harness 40 to theinsert 10. It is also preferable for some amount of adhesive to beapplied between and adhere the buffer sub-layer 38 and the heatersub-layer 26 to each other.

[0032] During the lamination process, it may be preferable for thelaminator 80 to expose various portions of the first layer 14 todifferent temperatures. For the embodiment illustrated, it is preferredthat the laminator 80 expose a first side of the first layer 14 (e.g.,the side that includes the buffer sub-layer 38 and the heater 26) to ahigher temperature while exposing a second opposite side of the firstlayer 14 (e.g., the side having the film sub-layer 28 and outermostadhesive sub-layer 34) to a lower temperature. Depending upon thematerials used, the difference between the higher and lower temperaturesis preferably between about 5° C. and about 150° C., more preferablybetween about 10° C. and about 100° C. and even more preferably betweenabout 20° C. and 80° C. In this manner, the central adhesive sub-layer34 of the first layer 14 is exposed to higher temperatures and isinduced to more substantially melt and adhere the barrier sub-layer 28to the heater sub-layer 26. At the same time, the outermost adhesivesub-layer 34 of the first layer 14 is maintained at a lower temperaturethan the central adhesive sub-layer 34 thereby avoiding excess meltingof the outermost adhesive sub-layer 34.

[0033] The sub-layers 36, 26, 28 are preferably fed to the laminator 80from rolls or otherwise and are cut to shape to form the first layer 14after lamination. The first layer 14 may be cut to nearly any desiredshape or configuration. In the illustrated embodiment, the first layer14 is cut to be generally rectangular and to include an extension 84 anda plurality of through-holes 86. In FIG. 1, the through-holes 86 arearranged in a generally rectangular configuration and are eachsubstantially the same size. In FIG. 3, however, the through-holes 86are shown in a preferred configuration as progressively becoming largerfrom one side of the insert 10 to another.

[0034] Referring to FIG. 3, the through-holes 86 preferably increase insize as the distance of the holes from the blower increases. Thisincrease in size provides a more uniform flow of air throughout theinsert 10. It is believed that the increase in the total cross-sectionalarea of through-holes 86 as the distance from the blower increasesallows air to enter or exit the openings at a more uniform rate than ifthe cross-sectional areas of through-holes at different distances fromthe blower were equal. The increase in cross-sectional area can beachieved by increasing the size of the holes, the number of holes, or acombination thereof. Finally, the increase in the cross-sectional areaneed not be a strict progression for each and every through-hole,rather, the through-holes in a region further from the blower shouldhave a greater cross-sectional area than the through-holes in a regioncloser to the blower. Through-holes 86 may also be provided in a varietyof different patterns. According to one preferred embodiment,through-holes 86 are provided in a substantially “U” shapedconfiguration corresponding to the legs and seat of the occupant.According to an alternative embodiment, through-holes 86 may be providedin a linear or straight line pattern (for example, to correspond to theback of an occupant) or in a variety of other patterns. Such pattern maybe influenced by the portion of the seat in which the insert is used andthe portion of the body of the occupant nearest the insert. According toother alternative embodiments, the number, size, shape, and pattern ofthrough-holes 86 may vary.

[0035] The rearward layer 20, like the front layer 14, is alsopreferably formed by attaching it sub-layers 62, 70 in a laminationprocess. Referring again to FIGS. 1 and 2, the barrier sub-layer 66, theprotective sub-layer 68 and the adhesive sub-layer 70 are fed to alaminator 90 (e.g., a belt laminator) such that the barrier sub-layer 66is between and attached to the adhesive sub-layer 70 and the protectivesub-layer 68. Thereafter, the rearward layer 20 is cut to have a shapesubstantially corresponding to the first layer 14. Of course, it iscontemplated that the rearward layer may be cut into a variety of otherconfigurations as well. Preferably, the rearward layer 20 includes athrough-hole 98 as shown in FIG. 3 through an extension 100 of therearward layer 20 that corresponds to the extension 84 of the firstlayer 14. It is contemplated, however, that the through-hole 98 may alsobe formed in the forward layer 14 if desired.

[0036] Once the middle layer 16 has been appropriately cut or otherwiseshaped to the proper configuration, which preferably corresponds to theforward and rearward layers 14, 20, each of the layers 14, 16, 20 arelaminated together to attach the layers 14, 16, 20 to each other. Asshown, the middle layer 16 may be cut to include an extension 96corresponding to the extensions 84, 100.

[0037] In the preferred embodiment, the layers 14, 16, 20 are laminatedin a stationary lamination device 104 at elevated temperatures such thatthe adhesive sub-layer 70 of the rearward layer 20 and the outermostadhesive sub-layer 34 of the forward layer 14 both adhere and attach theforward layer 14 and the rearward layer 20 to the middle layer 16 (e.g.,the honeycomb structure). At the same time, it is preferred that thebarrier sub-layer 28 of the front layer 14 and the barrier sub-layer 66of the rearward layer 20 be adhered to one another about an outerperipheral strip 106 of the insert 10. It is also preferred that theattachment component 72 be sandwiched and attached between at leastportion of the rearward layer 20 and the middle layer 16 although theattachment component may be otherwise attached (e.g., retrofit,fastened, or the like).

[0038] The strip 106 may have a width as high as four (4) centimeters orgreater. Preferably, the strip is between about 0.2 cm and about 3 cmand more preferably between about 1.0 cm and 2.0 cm. Advantageously, theadhesive sub-layers 34, 70 and the outer laminated peripheral strip 106separately and together assist in forming the insert 10 as a tightlyintegrated unit wherein the layers 14, 16, 20 are substantially immobilerelative to each other.

[0039] While pre-cutting the layers 14, 16, 20 followed by laminatingthe peripheral edges of at least two of the layers 14, 20 have beendiscussed, it is contemplated that cutting of the layers 14, 16, 20 andlaminating of the layers may be integrated into a single processingstep. For example, it is contemplated that supplies (e.g., rolls) ofeach of the layers 14, 16, 20 may be provided to a machine thatlaminates outer edges of each of the layers 14, 16, 20 together forforming the peripheral strip 106 as the supplies continuously orintermittently provide the layer 14, 16, 20 to the machine. Thus,inserts 10 may be formed by cutting the inserts 10 with the peripheralstrip 106 from the laminated layers 14, 16, 20 and such cutting may beperformed by the laminating machine or by another cutting machine ordevice. In such an embodiment, it is contemplated that the through-holesin the forward layer 14 and the through-hole in the rearward layer maybe formed prior to, during or after lamination forming the outerperipheral strip 106.

[0040] Although laminating the edges of the film together and the use ofadhesive layers have been found particularly advantageous, it iscontemplated that other methods of attachment may also be employed inconjunction with the laminated edges or separately. For example a robotmay be employed to apply a variety of adhesives such as hot-melt, heatactivated, encapsulated or other types of adhesives. In one preferredalternative, an encapsulated adhesive may be applied to a first layerfollowed by breaking the encapsulated adhesive in close time proximityto attaching a second layer to the first layer. In other preferredembodiments, it is contemplated that the plastic films may be fusedtogether with other techniques such as those used for book binding.Moreover, mechanical attachments (e.g., snaps, zippers, sewing,stitching, stapling or the like) may be used alone or in conjunctionwith the plastic films and adhesives.

[0041] During final assembly 110, the wire harness 40 is preferablyinserted within the pocket formed by the tape 36 or otherwise attachedto the insert 10. Also, a blower, the housing 120 of which is shown inFIG. 5, is preferably attached to the attachment component 72 of theinsert 10. In the embodiment shown, the housing 120 include flanges 124suitable for snap-fitting the housing 120 to the attachment component72. In this manner, the blower can be attached to the rest of the insert10 and can be placed in fluid communication with the through-holes 86 ofthe first layer 14, the open space 58 of the middle layer 16 and thethrough-hole 98 of the rearward layer 20. Advantageously, the attachmentcomponent 72 and flanges 124 provide a unique and efficient method ofattaching the blower to the insert 10. It is contemplated however, thatvarious other methods of attachment (e.g., fasteners, sewing, matingthreaded attachments, quick connects or the like) may be used to attachthe blower to the insert 10. It is also contemplated that the attachmentcomponent 72 and the housing 120 and flanges 124 of the blower may bevaried within the scope of the present invention.

[0042] For assembly of the insert 10 to a vehicle seat (not shown), theinsert 10 is preferably connected (e.g., sewn, adhered or otherwiseattached) to a portion of the seat such as the cover (e.g., a perforatedleather cover) or to a cushion (e.g., foam) of the seat. In onepreferred embodiment, a seat cover may be configured to include a pocketfor receiving the insert 10. Alternatively, it is contemplated that hookand loop fasteners may be utilized to attach the insert 10 to portions(e.g., the cover or foam) of the seat.

[0043] The insert 10 is preferably positioned in the seat such that thefirst layer 14 is closer to the outer seat cover relative to therearward layer 20 although not necessarily required. It is alsopreferable for an extension 139 formed by the extensions 84, 96, 100 ofthe layers 14, 20 to extend behind the cushion of the seat such that theblower may be attached to a portion of the frame of the vehicle seat.Preferably, the extension 139 is a tubular structure for providing fluidcommunication between the open space of the spacer layer 48 and theblower. Additionally, the wire harness 40, the heater sub-layer 26, theblower or a combination thereof are preferably connected in signalingcommunication with a control unit 130 and/or each other. The controlunit 130 may be separate from or integrated into the vehicle.

[0044] In one embodiment referring to FIGS. 3, 4 and 6, the insert 10 isformed with one or more (e.g., three) through-holes 140 that extendthrough the layers, sub-layers or both of the insert 10 such that thethrough-holes 140 extend entirely or substantially entirely through theinsert 10. Preferably, the insert 10 (e.g., the barrier layers 28, 66)have a seal 141 about the through-holes 140 for substantially preventingdirect fluid communication between the through-holes 140 and the openspace 58 within the insert 10. In the embodiment depicted, the barriersub-layers 28, 66 are attached to each other during the laminationprocess to form a substantially air-tight seal 141 about thethrough-holes 140.

[0045] Advantageously, the through-holes 140 can assist in the assemblyof the insert 10 and/or a seat cover 142 to a seat 144 of an automotivevehicle. As shown, for each through-hole 140, a portion 148 (e.g., acushion layer, a felt layer, a leather layer, combinations thereof orthe like) of the seat cover 142 is extended through the through-hole 140and is attached to foam 154 of the seat 144. In the embodiment depicted,the portion 148 is attached to the foam 154 by wrapping or otherwiseattaching the portion 148 about a member 162 (e.g., a bar or wire) thatis attached to (e.g., at least partially imbedded within) the foam 154.Additionally, one or more loops 166 (e.g., metal loops) are integratedwith the portion 148 and are looped about the member 162 for assistingin attaching the portion 148 to the member 162.

[0046] It shall be appreciated that, in embodiments alternative to theone depicted, a variety of materials or members such as wire, thread,stitches, fasteners, foam or the like may extend through thethrough-holes 140 in the insert 10 for assisting in the attachment ofthe seat cover 142, the insert 10 or both to the other components of theseat 144. Moreover the materials or members may be connected to the seatcover, the foam, the seat frame, other portions of the seat or vehicleor the like depending on the desired configuration. It is alsocontemplated that other attachment methods such as the use ofalternative fastening devices may be employed in addition to oralternative to the through-holes 140. For example, hook and loopfasteners, sewing, adhesives or other fastening devices or mechanismsmay be employed to locate the insert 10 relative to the seat cushion,the seat cover 142 or both.

[0047] While it is generally preferable that the layers 14, 16, 20 besubstantially coextensive with each other and that the rearward andforward layers 14, 20 form a substantially continuous seal or peripheralstrip 106 about the insert 10, it is contemplated that such is not thecase. Thus, it is contemplated that one or more of the layers 14, 16, 20may be less than coextensive with each other or non-existent. Forexample, the rearward layer 20 alone could provide a barrier sub-layer66 that provides a sufficient pathway for receiving air from theextension 139 and guiding air through the spacer layer to the seat cover142 or trim layers.

Operation

[0048] In operation, the insert of the present invention can preferablyprovide heating, cooling, ventilation or a combination thereof to anoccupant of a seat having the insert. In particular, if heat is desired,electric current can be induced to travel through the heater sub-layer26 by the control unit 130 or otherwise such that the heater sub-layer26 can provide heat to the occupant.

[0049] Alternatively, if cooling or ventilation is desired, the blowercan be operated via the control unit 130 or otherwise to pull airthrough the through-holes 86 in the first layer 14 of the insert 10,through the open space 58 of the middle layer 48 of the insert 10 andthrough the through-hole 98 of the rearward layer 20. Such airpreferably flows at least partially past the occupant of the seat andthrough the seat cover (e.g., a perforated leather seat cover or clothseat cover) thereby providing ventilation to the occupant and providingconvective heat transfer from the occupant to the flowing air.

[0050] Although, it may be preferable for only the heater sub-layer 26or the ventilation system to be running at one time, it is contemplatedthat both may be operated simultaneously. Moreover, it is contemplatedthat both the heater sub-layer 26 and the ventilation system may beoperated at various levels (e.g., 2 or more levels of output) such as byhaving a blower that can operate at different levels or by havingvarious levels of electricity flowing thought the heater sub-layer 26.It is also contemplated that the blower may push air into the open space58 of the insert 10 as well as pulling air from the open space 58.

[0051] It is also contemplated that one or more temperature sensors(e.g., a thermostat) may be included adjacent the insert, the trim layeror the like. Preferably, any temperature sensors are near the seat coveror the insert for sensing a temperature closely related to (e.g., at ornear) a temperature being experienced by an individual in the seat. Suchtemperature sensors may be in signaling communication with the controlunit 130 such that the control unit 130 can control the blower 22, theheater layer 28 or both for attaining or maintaining a desiredtemperature at areas adjacent the individual and/or the temperaturesensor. Moreover, the control unit 130 may be programmed withinstructions for commanding the blower 22, the heater layer 28 or bothto change output levels (e.g., turn on or turn off) if the temperaturesensor senses a temperature above or below one or more threshold levels.An example of such programming is described in a copending patentapplication titled “AUTOMOTIVE VEHICLE SEATING COMFORT SYSTEM”, serialNo. 60/428,003, filed Nov. 21, 2002 and incorporated herein by referencefor all purposes.

[0052] Advantageously, the plastic film sub-layers 28, 66 respectivelyof the first and third layers 14, 20 provide a substantially gas-tightseal about the middle layer 16 (e.g., the spacer sub-layer 48). In thismanner, gas flow to and from the open space 58 of the spacer sub-layer48 is substantially restricted to flowing through the through-holes 86,98 of the first and third layers 14, 20.

[0053] In a highly preferred embodiment, the through-hole 98, which maybe defined by the sub-layers 66, 70 of the rearward layer 20 or by theattachment component 72, spans an area no greater than about 100 cm² orhigher, more preferably between about 15 cm² to about 60 cm², even morepreferably between about 25 cm² and about 40 cm² and most preferablybetween about 30 cm² and about 35 cm² depending upon the size of theblower. Advantageously, for maintaining more efficient flow of air, thethrough-holes 86 on the front layer 14 may be sized to span areas, thesum of which, is substantially similar (e.g., within 20 cm², morepreferably within 10 cm² and even more preferably within 5 cm²) to thearea of the through-hole 98 in the rearward sub-layer 20. Additionally,the open space 58 of the middle layer 58 may be sized such that nearlyany cross-section substantially perpendicular to airflow therethrough isalso substantially similar (e.g., within 20 cm², more preferably within10 cm² and even more preferably within 5 cm²) to the area of thethrough-hole 98 in the rearward sub-layer 20.

[0054] The preferred embodiment of the present invention has beendisclosed. A person of ordinary skill in the art would realize however,that certain modifications would come within the teachings of thisinvention. Therefore, the following claims should be studied todetermine the true scope and content of the invention.

What is claimed is:
 1. A ventilated seat for a vehicle, comprising: avehicle seat having a seat cushion component and a seat backrestcomponent, at least one of which is ventilated, each ventilatedcomponent having an air-permeable trim surface at the occupant contactareas of the seat; an insert located beneath the trim surface of eachventilated component, the insert including: i) a forward layer having aheater sub-layer; ii) a rearward layer having a barrier sub-layer; andiii) a middle layer having a spacer sub-layer defining an open spacewherein at least one of the forward layer and the rearward layer isadhesively secured to the middle layer; and an air mover attached to theinsert in fluid communication with the open space of the spacersub-layer.
 2. A ventilated seat as in claim 1 wherein insert includes anextension that extends behind the cushion of the seat to the air mover.3. A ventilated seat as in claim 1 wherein the insert is positionedbetween a foam cushion of the vehicle seat and the air-permeable trimsurface.
 4. A ventilated seat as in claim 1 wherein at least onethrough-hole extends through the insert and a barrier sub-layer of theforward layer and a barrier sub-layer of the rearward layer seal aboutthe at least one through-hole to prevent fluid communication between theopen space of the spacer sub-layer and the at least one through hole. 5.A ventilated seat as in claim 4 wherein a material extends through theat least one through-hole for assisting in securing the insert to theseat cushion component.
 6. A ventilated seat as in claim 1 furthercomprising a control unit in communication with the air mover and theheater sub-layer.
 7. A ventilated seat as in claim 6 wherein the controlunit is programmed with instructions for commanding the air mover andthe heater sub-layer to change output levels if a temperature sensorsenses a temperature above or below one or more threshold levels.
 8. Aventilated seat as in claim 1 wherein a plurality of through-holesextend through the forward layer and the through-holes get progressivelylarger from one side of the insert to another.
 9. A ventilated seat asin claim 1 wherein the forward layer includes a barrier sub-layerlaminated to the heater sub-layer with a hot melt adhesive sub-layer.10. A ventilated seat as in claim 1 wherein in at least one of theforward layer and the rearward layer are laminated to the middle layerwith an adhesive.
 11. A ventilated seat for a vehicle, comprising: avehicle seat having a seat cushion component and a seat backrestcomponent, at least one of which is ventilated, each ventilatedcomponent having an air-permeable trim surface at the occupant contactareas of the seat; an insert located beneath the trim surface of eachventilated component, the insert including: i) a forward layer having afirst barrier sub-layer and a heater sub-layer, said forward layerincluding a plurality of first openings; ii) a rearward layer having asecond barrier sub-layer, at least one of the rearward layer and theforward layer including at least one second opening; and iii) a middlelayer having a spacer sub-layer defining an open space; and an air moverattached to the insert and in fluid communication with the plurality offirst openings and the open space; wherein the first barrier sub-layeris sealingly attached to the second barrier layer about a periphery ofthe insert.
 12. A ventilated seat as in claim 11 wherein the insertincludes an extension that extends behind the cushion of the seat to theair mover.
 13. A ventilated seat as in claim 11 wherein the insert ispositioned between a foam cushion of the vehicle seat and theair-permeable trim surface.
 14. A ventilated seat as in claim 11 whereinat least one through-hole extends through the insert and the barriersub-layer of the forward layer and the barrier sub-layer of the rearwardlayer seal about the at least one through-hole to prevent fluidcommunication between the open space of the spacer sub-layer and the atleast one through hole.
 15. A ventilated seat as in claim 14 wherein amaterial extends through the at least one through-hole for assisting insecuring the insert to the seat cushion component.
 16. A ventilated seatas in claim 11 further comprising a control unit in communication withthe air mover and the heater sub-layer wherein the control unit isprogrammed with instructions for commanding the air mover and the heatersub-layer to change output levels if a temperature sensor senses atemperature above or below one or more threshold levels.
 17. Aventilated seat as in claim 11 wherein the openings of the plurality ofopenings in the forward layer get progressively larger from one side ofthe insert to another.
 18. A ventilated seat as in claim 11 wherein theforward layer includes a barrier sub-layer laminated to the heatersub-layer with a hot melt adhesive sub-layer.
 19. A ventilated seat asin claim 11 wherein in at least one of the forward layer and therearward layer are laminated to the middle layer with an adhesive.
 20. Aventilated seat as in claim 11 further comprising a rigid attachmentcomponent secured to at least one of the forward layer, the rearwardlayer and the middle layer wherein the attachment component includes athrough-hole aligned with the at least one second opening.
 21. Aventilated seat as in claim 20 wherein the air mover includes a housinghaving flanges and wherein the flanges are attached to the attachmentcomponent.
 22. A ventilated seat for a vehicle, comprising: a vehicleseat having a seat cushion component and a seat backrest component, atleast one of which is ventilated, each ventilated component having anair-permeable trim surface at the occupant contact areas of the seat; aninsert located beneath the trim surface of each ventilated component,the insert including: i) a forward layer including a first barriersub-layer formed of a plastic material, a heater sub-layer formed as alay-wire heater, and a plurality of openings; ii) a rearward layerhaving a second barrier sub-layer formed of a plastic material, saidrearward layer including at least one opening; and iii) a middle layerhaving a spacer sub-layer defining an open space, the spacer sub-layerbeing formed of interwoven polymeric strand material; a blower attachedto the insert and at least partially disposed within the at least oneopening of the rearward layer, the blower in fluid communication withthe plurality of openings in the forward layer and the open space;wherein the first barrier sub-layer is sealingly attached to the secondbarrier sub-layer about a periphery of the insert and wherein the bloweris configured to pull air through the plurality of openings in theforward layer and through the open space of the spacer sub-layer.
 23. Aventilated seat as in claim 22 wherein at least one of the forwardlayer, the rearward layer and the middle layer form an extension thatextends behind the cushion of the seat to the air mover.
 24. Aventilated seat as in claim 22 wherein the insert is positioned betweena foam cushion of the vehicle seat and the air-permeable trim surface.25. A ventilated seat as in claim 22 wherein includes at least onethrough-hole extends through the insert and the barrier sub-layer of theforward layer and the barrier sub-layer of the rearward layer seal aboutthe at least one through-hole to prevent fluid communication between theopen space of the spacer sub-layer and the at least one through hole.26. A ventilated seat as in claim 25 wherein a material extends throughthe at least one through-hole for assisting in securing the insert tothe seat cushion component.
 27. A ventilated seat as in claim 22 furthercomprising a control unit in communication with the blower and theheater sub-layer wherein the control unit is programmed withinstructions for commanding the blower and the heater layer to changeoutput levels if a temperature sensor senses a temperature above orbelow one or more threshold levels.
 28. A ventilated seat as in claim 22wherein the openings of the plurality of openings in the forward layerget progressively larger from one side of the insert to another.
 29. Aventilated seat for a vehicle, comprising: a vehicle seat having a seatcushion component and a seat backrest component, at least one of whichis ventilated, each ventilated component having an air-permeable trimsurface at the occupant contact areas of the seat; an insert locatedbeneath the trim surface of each ventilated component, wherein; i) theinsert is sealed about a peripheral edge; and ii) the insert includes aspacer material forming open space within the insert; and iii) theinsert includes at least one first opening and a second opening; and anair mover in fluid communication with the first opening, the secondopening and the open space of the spacer sub-layer.
 30. A ventilatedseat as in claim 29 wherein the insert includes a resistive heatingelement disposed thereon.
 31. A ventilated seat as in claim 30 whereinthe insert includes an extension of substantially smaller width than therest of the insert wherein the extension extends behind the cushion ofthe seat to the air mover.
 32. A ventilated seat as in claim 31 whereinthe air mover includes a fan.
 33. A ventilated seat as in claim 32wherein the air mover is configured to pull air through the firstopening, then through the open space to the air mover.
 34. A method offorming a ventilated seat, comprising: providing a forward layer havinga forward barrier sub-layer, a heater sub-layer; forming a plurality offirst through-holes in the forward layer; providing a rearward layerhaving a rearward barrier sub-layer; providing at least one secondthrough-hole extending through at least one of the forward layer and therearward layer. providing a middle layer having a spacer sub-layer; andlaminating at least the forward layer to the rearward layer about aperipheral strip with the middle layer being substantially encapsulatedby the forward layer and the middle layer.
 35. A method of forming aventilated seat as in claim 34 wherein the step of providing a forwardlayer includes laminating the heater sub-layer to the forward barrierlayer with an adhesive.
 36. A method of forming a ventilated seat as inclaim 34 wherein the middle layer is secured to at least one of theforward layer and the rearward layer during the step of laminating theforward layer to the rearward layer.
 37. A method of forming aventilated seat as in claim 34 further comprising providing a rigidattachment component adjacent the second through-hole and securingflanges of a blower housing to the attachment component for allowing ablower to be in fluid communication with the second through-hole.
 38. Amethod of forming a ventilated seat as in claim 34 wherein the heatersub-layer is provided as a carbon-fiber heater laminated to gauze.
 39. Amethod of forming a ventilated seat as in claim 34 wherein the rearwardlayer includes a sub-layer adhesively laminated to the rearward barrierlayer.
 40. A method of forming a ventilated seat as in claim 39 whereinthe heater sub-layer is adhesively secured to the forward barrier layerand the forward layer and the rearward layer are adhesively secured tothe middle layer.